Apparatus for forming wheels



APPARATUS FOR FORMING WHEELS Original Filed June 13. 1921 2 Sheets-Sheet 1 g lt} I Sept. 25 1928. 1,685,513

' C L WILBER APPARATUS FOR FORMING WHEELS Original Filed June 13, 1921 2 Sheets-Shut 2 1 1 1 B QQ Patented Sept. 25, 1928.

UNI ED STATES 1,685,513 PATENT orrlcs;

"cam, L. WILBER, or DETROIT, MICHIGAN, ASSIGNOR To JEFFERSON FORGE PRODUCTS com any, OF-DETROIT, MICHIGAN, A CORPORATION or MICHIGAN.

APPARATUS FOR FORMING WHEELS.

Original application fil'ed Iiine 13,192 1, Serial No. 477,083. ivided and this application filed April 7, i 1923- Serial No. 630,511. I

The general object'of my invention is to provide a satisfactory and economical method and means for forging complete vehicle vvheels or partsthereof, to produce 5 in a single piece drop-forging an entire wheel that may include felloe, lugs, spokes, center'disk, hub, brake drum and reinforcing webs (thus making the wheel available as the rear wheel of an automobile) or'that may include any less number'of the stated parts or their equivalent-s. v

This application is a division of my copending application, SerialNo. 477 083. filed June 13, 1921. The claims of the present application are drawn to the improved and novel forms of punching devices for shearin the tong-hold or tail from the felloe of the wheel and for trimming the spokedwheel forging as a finishing operation.

In the drawings Fig. 1 indicates a slab or bar of steel suitable for forging; Fig. represents diagrammatically means for blocking a. blank and the blank after tliis operationhasbeenperformed; Fig. 3 represents a means for blank-punching and the punched blank; Fig. 4; represents means for forge-linishing, the blank and the finishforged blank; Fig. 5 represents diagrammatically a tong-hold removing operation;

' and Fig. 6 represent-s diagrammatically a blanl: trimming means andthe trimmed completed blank or forging.

For conversion of a simple',rolled-metal slab as shown in Fig. 1 into a forged wheelform of a relatively complex nature as shown in Fig. G wholly by forging and. punching operations I employ specially designed tools in the way of blocking dies, blocked-blank punching dies; finished-forging dies, tonghold removing dies, andtrimmingdies, all used in connection with standard steam drop-forginghammers, punch presses and heating furnaces, such standard devices being found in all forge-shops and needing no detailed description. The preferredv se quence of operations and the special tools therefor I will not describe but it will be understood that, while it is advantageous to follow the full course of operations so to be described, changes of method and of apparatus may be made in some particulars without departure (by reason of retention of pther procedural steps and apparatus that tong-hold, it may here be understood, is

preserved throughout thesequence'of operations until the metal has been heated for the lasttime, so as to permit facile handling of the article with the usual tongs at all nee: V

essary stages of development, and all for{;--

ing dies and punching dies that are em ployed' before the tong-hold or, tail t is removed have suitable marginal openings or clearances for thereception thereof. All

forging operations are effected by mated,

horizontal dies, recessed in their confront steam-hammer. V

The slab A is first subjected to a blockiorging operation to secure a preliminary dis tribution of the, metal into zones of different thicknesses, that roughly speaking, will be proportional 'to the demand for metal to constitute the different circular-zones of the complotedwheel or part of a wheel; namely, inthe illustrated instance, the felloezone, spoke zone and center-body zone of the wheel. The slab Ais heatedto proper forging temperature, say approximately 1900 degrees F., with a slow fire and the hot blank A forged between the upper and lower dies B, B, respectively keyed to the ram and the sow-block anvil of a suitableha1n men (not shown) to bring the blank to the blocked form shown at. A (Fig 2). Generally speaking, the blocked blank A should take circular form with a felloe mass a" of substantial thickness (i. e., measurement transversely to the plane of the wheel) approximating the felloe or rim width; with a thinner spoke-zone .web a of approximately spoke-thickness or somewhat more; and

with a center-body mass 0, that should preferably be closely figured in metal content to the requirements of the finished centerbodyQj Where huband brake-drumforma tion is desired, an annular flange mass a, is forn'ied onone side of the blank and the center of the blank is thickened preferably mg surfaces, and operatedby a standard on both sides of the blank to form a relas zone surfaces 72 and 6' and hub-mass recessesb and Z), the latter recesses-being surrounded, in the upper die B by the annul a'rflange-recess b e a It is important, in the formation of the particular block-blank A shown, that the metal massa for hub-formation shall not exceed the demand for metal to constitute the final hub-block and it is desirable that the entire center-body mass shall not contain excess metal, but that, tothe contrary, it

'ishallbequite-accurately figured as to content or tend slightly toward deficiency in metal-mass. spoke-web shall have its minimum thickness adjacent ;to the center body and shall be slightly thickened toward the outermost margin,'any surplus of stock in the blockblanking'being forced toward the margin and utilized] in felloe-formation or. marginally extruded from the die-cavities. This special care in the proportioning of center body cavitiesin'block-forming is necessary onlywhen the forged center is to be solid,

as when a hub-block is desired, so as to pre- 7 vent trapping of excess metal that may cushion thesubsequently-employed dies. 'In general it will be understood that, since 1 this blocked-forged blank represents only an intermediate stage in development of the completed article, it is notessential that the blocked-blank A shall have absolute regularity of contour nor the precise diameter of the finished product The greater the approximation of regularity and uniformity of contour that may (without undue-ex- I pense) be had in the blocking of the blank, however, the easier and more uniform are made subsequent V operations thereon and therefore special provision for the rapid and uniform blocking is to be preferred.

As illustrated the shaping of the diesis such as to give a quick flow of metal toward the periphery.throughout the spoke-zone hand to afford smooth inclines or curves to insure desired: flow of metal to the center body zone; Of course if integral hub structure or integral intake-band flange be not .I'(f5q111I6d the dies will be changed in conformation.

Before finish-forging this blocked blank I remove surplus metal from the zone or accordantly zones that, by reasonof intended ultimate I (EU perforation, may best suffer the removal and that; by virtue of position, will afford best relief areas for escape of residual excess of metal n the finish-forging operation, all in l accordance with the demands of the wheel or wheel-structure ultimately to ,be pro- Also it is preferable that the e duced. 'In respect of the particular construction shown I preferably remove the excess metal from the spoke-zone and preferably perform this operation in the manner illustrated in Fig. 3, .The blocked the lower die, strike out segments of the spoke-zone of the blank so converting it to the spoked-blank form indicated at A in Fig. The stripper plate maybe normally raised by spring sustained stop guides 17 to stand at the upper end of the very limited range of motion and it serves to strip the blank from the cutting projections 13 as the upper 'die rises. This punching operation may well be performed while the blank is still relativelyhot, and should of course leave the'spoked-blank A with spoke-strips a that, in number and angular position, correspond with the demands of the finished wheeh Although throughout the operations thus far described it is desirable roughly to approximate the ultimate contours of the different zones, with fairly uniform distribution of metal circumferentially or angularly throughout the blank ac cordantly with the metal disposition to be made in the finished forging, substantial deviation, intentional 'or otherwise, from this ideal may readily be overcome in the finishing operations to bedescribech-and in deed, the spoked, blocked blan'kmay be produced in other ways.

The punched blanl; or spoked-blank A should again be brought to forging temperature andthen issubn'iitted to the operation of the forge-finishing dies C, C, that of course are fixed respectively in the ram and the sow-block of a suitable hammer. These dies have inated or complemental circular. and radial cavities, with flash-clearances, and gutters, accurately tofbring the .;properlysized and shaped spoked-blank to finished contour throughout all of the cavity-received portions, that is to say. to bring it to finished shape exceptfor flashes, of extruded, excess metal and for the tong-hold. In the specific construction shown the dies C, C are preferably divided 'on'such a line that the recess 0 of the lower'die provides the entire forming face for the exterior surface ofv the felloe in order that, desirably, the felloe or rim may present a fru'sto-conoidal :eXterior, and marginally beyond both felloerecesses c and o of the'upper and lower dies annular gutters 01 are provided, while along the innermargins of the felloe=grooves oi dies certain lug-forming recesses 0 may be made. Where spokes of concaveconvex or parti-tubular cross-section are desired complemental spoke-channeling proj ect-ions o and spoke grooves may be pro,- vided in the upper and lower dies, these merging into the appropriately formed surfaces for forming the center-body. Thus upper die Cris shown annularly recessed at 0 for the formation of a brake-drum flange and as centrally recessed as at a? for the format-ion of a hub-part while the lower die is recessed only as at c for a hub-part. Grooves a in the upper die may provide for the formation of radial ribs on the wheel between the hub and the brake-drum flange. Shallow escape-tolerance for the extrusion of a flash throughout the area between spokes is provided between the dies and it is my preference that the central portion of each interspoke segment be recessed or guttered as at 0 Thus, in the finish-forged blank A as shown in Fig. t a flash, preferably thin at its line of juncture with the body of the casting and thicker at a. little distance from said body borders the felloe and also borders entirely each segmental interspace between spokes, as indicated respectively at a and a in Fig. 4.

It will be understood that according to the specifications of different wheels or wheelstructures less than the full device shown, details may vary from those above described, but in general it is desirable that the finishing-die contours should afford ample facility for flow of metal to those zones (such as the rim Zone) where excesses of metal may best be taken care ofand find escape as flashes; and that flashes shall be formed as a thin strengthening and stiffening web, lying in the plane of the work, in those areas that are ultimately to be open spaces and preferably may also form a web about the perimeter of the forging. Thus the blank A as fashioned in the finishing dies embodies the complete contour of the finished article but with the addition of the flashes aforesaid. It is to preventpocketing or trapping of metal in the central cavities, with resultant detriment in preventing the blank from being properly reduced by dies C, C, that careful proportioning of the cen tral mass of the blocked blank is most desirable.

The forge-finished blank, A with its flash-webs undisturbed, is annealed before any further shaping operation takes place, in order to relieve the metal of forging-stresses, and warping tendencies and in order to prepare it for easy trimming; and it is noteworthy that notwithstanding the tortuous effect that is inevitable in wide-spreading, re-massing and reducing of metal to such ex tremes as arerepresented by the formation of the described automobile wheel or in any such forging operations as above described, the flash-carrying blank in nearly every in- .into the open spaces of the shoe.

stance stands annealing without any such warpin or loss of shape as would require reshaping. This highlydesirable and economical c aracterist-ic I ascribe not merely to the uniformity .of action in the forging, but in very material measureto the presence of the highly-condensed flash-web lying in what I may term the plane of work, that is to say, in'the generally fiat or slightlydished conformation into which the forgefinished blank has been brought. V

The annealed blank may now be allowed thoroughly to cool with its flash-web intaot, and then the blank is subjected to a cold trimming. First its tong-hold may be removed by a punching operation as indicated in Fig. 5.

In this operation the felloe-perimeter is brought into contact with two gauge-pins 30 on a die-plate 31 whereon the tong-hold and wheel fclloe are firmly seated. Such plate has apunch-receptive opening 32 shorter than the length of the tong-hold and I with its front edge conformin to the are of the felloe. The tong-hold, t us receiving support on both sides of the orifice 32, is struck by the punch 33 that corresponds in shape with orifice 32 and thusissheared off,

together with a fragment of the perimeteral flash. I find that by shearing in this way cutting the tong-hold at two points simultaneously at the front and rear of the orifice 32,there is no danger of distorting the wheel and the cut is cleanly and adequately made.

Next the flash-carrying blank. A is trimmed to the final condition shown at A in F ig. 6 preferably by cutting mechanism as therein shown. The flash-carrying blank is laid on the shoe 40, which is bolted to the bed-frame plate of a punch-press, this shoe having deep circular and radial recesses 41 and 42, appropriate to receive the wheelproper and having fixed circumferential and segmental cutting dies 43 anl 4A. respectively. these conforming to the perimeter of the felloe and to the spoke interspaces to be trimmed. So positioned the blank is struck by the punch 45 that is shaped smoothly to the uppermost contours of the wheel-proper and throughout its perimeter and along the spokeinter'spac'es to coact with the die surfaces of the shoe, thereby to shear theivheel from the flashes and to force the wheel down Specifically/l6 indicates the felloe-trimming edge; 47 the spoke-fitting surfaces and 48 the center, grooved to fit with the wheel center-body. Spring-pressed retaining points 50 protruding from the spoke-interspace portions of the punch strike upon, and retain in position, the inter-spoke flashes; and a lift block 51, arranged in the peripheral recess of the shoe 40 and carried in vertical reciprocation by the rod 45* of the punch 45, serves, upon the movement of the punch 45 away from the .ajmann'ertha't the punch diemay be fully moved upon the shoe 40, and, during its reverse movement, the lift block may be picked up by the rods' ifr and the finished wheel raised as explained .I find that this finishpunching operation has a beneficial straight- 'ening tendency, .eitectually truing"in the fiat wheels that may be slightly out of true when presented to the press;

The operations heretofore described com-:

plete the wheel subject only to final machining operations such as the final surfacing of a brake-drum, boring out of the hub, surfac ing the felloe, tapping of apertures for tie l sired attachments, etc, and the speed and facility' with which'the substantially complete unitary wheel can be produced renders its manufacture one of most desirable economy. I 'findit to be desirableand economical and therefore prefer, to make the wheel from slab to the substantially complete form shown by the forging and punching method described, because all operations andj'part'icul'arly thepreliminary onesto bring the blank! into its intermediate blocl-t-forgc'c and punched state, may be performed 'in quantity With rapidity and low expense'and the successive forging operations are beneficial, in insuring a homogeneous, flawless body of metal throughout the structure with especial finenessof grain and toughness in the relatively thin sections such, particularly, as thespoke sections and the center-disk secs t'ion betweent'he hub and lateral flange (herd. tofore referred to as abrake-drnm flange but that may be any strengthening flange). It is, however, feasible, with retention of part of the benefits of my invention, to opcr'ateon a cast steel blank in any stage of development up to that represented above as a block forged and spoke-punched blank; and in other respects portions of the full process and apparatus above set forth may be employed with corresponding retention of benefits and advantages through the utilization of feainvention.

1 A finishing trimmer for spoked-wheel forgings comprising a lower die having wheel receptive cavities, a" punch die coacting with the lower die to strike the wheel into said lower die, a lift block in said lower die cavities, means for raising and lmymiing Said 11f b10 1 and plungers in said punch die for coasting w th the interspoke flashes. i

2. A finisliingtriminer for sp'oked-wheel forgings comprising a lower die having the interspoke flashes for retaining the same in position as the punch die is actuated;

4. A finishingtrimmer for 'spcked-wheel forgings comprising a'lowcr die adapted to support affiash-carrying blank, said lower die having spoke and 'rima'eceptive' cavities and cooperating cutting surfaces, a punch dieshaped and operated to coactwith the die surfaces of said lower die to shear the I wheel from the, flashes and force the same down into said cavities, a lift ringfinsaid rim-receptive cavity, and rods each of which are directly connected o" both said punch (Lie and liftring 'for engaging and removing the trin'nned wheelfroni said cavities as said punch die is moved away from its lower die engaging'position. i V 7 i f 5. A; finishing trimmer for spokedqvheel forgiiigs comprising a lower die adapted to support a flash-carryingfblank, said lower di 1 having spoke and rim-receptive ca ities and cooperating cutting surfaces, apunch die shaped and operated to coa ct with the die surfaces of said lower diet shear the wheel from :the flashes and force it down into said cavities, plunge'rs carried by said punch die for retaining the inter-spokcd i "lies of the blank inposition 'a lift block .id m n-respective cavity, and i'odseacli of'which a'redirectly connected toboth said punch dieia nd said. lift block for engaging and removing theftrimmed wheelfrom said 0 'Viti'e's" as said [ninclidieisinoved'away from its low'eijdie engaging position.

6. A finisl'iingftrimmer for sp'oked-wheel forgings comprising adie having spoke and rim-receptive cavities and associated cutting surfaces adapted to initially support a flashcarrying wheel blank and to finally receive the samein'said cavities, anotherdie adapted to coact with said first die to shear the whee; from said flashes and force the wheel intosaid cavities, and means movable in said riin cavity and directly associated with said other die for engaging and removing the trimmed ivheel from said cavities as said other "die is'inoved ai'vay from the first die.

- CARL L. WILBER.

lift) CERTIFICATE OF CORRECTION,

Patent No. 1,685,513. Granted September 25, 1928, to

CARL L. WILBER.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 4, line 107, claim 5, for the compound word "rim-respective" read "rim-receptive"; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 6th day of November, A. D. 1928.

M. J. Moore,

(Seal) Acting Commissioner of Patents. 

